Method of weaving



April 1961 R. B. PATTERSON EIAL 2,981,291

METHOD OF WEAVING Filed June 22, 1960 2 Sheets-Sheet 1 FIG. 2.

YWYWWWIYI W Y W W W WWWW INJENTORS:

ARRY J. SMILEY H RAYMOND B. PATTER ON BY April 1961 R. BfPATTERSON ETAL 2,981,291

METHOD 0F WEAVING Filed June 22, 1960 FIG. 8. I;

2 Sheets-Sheet 2 FIGQ INVENLTEOYRS: \Q -Q HARRY J. SM M w BY RAYMOND B. PATTERSON ATT Y.

fl d SW 1 METHOD OF WEAVING Raymond B. Patterson and Harry J. Smiley, Glasgow, Va., assignors to James Lees and Sons Company, Bridgeport, Pa., a corporation of Delaware Filed June 22, 1960, Ser. No. 37,978

7 Claims. (Cl. 139-39) This invention relates to the weaving of pile fabrics and more particularly to an improved velvet floor covering.

The present invention has for its primary object the provision of a novel velvet carpet and method of weaving same characterized by an ample backing to bind multi-frame pile yarns weaving over alternate pairs of adjacent pile wirm.

A further object of the invention is to provide amethod of weaving a fabric in which the pile loops or projections in the same weftwise row are formed by different pile wires.

A further object of the invention is to provide a series of transverse rows of pile loops having alternate appearance and position in each row.

A further object is to provide a novel base fabric weave which produces a relatively rigid base for the fabric and to which the pile yarns are tied in only under every fourth weft.

A further object of the invention is to provide in a two shot velvet pile fabric construction a novel weave in which alternate top filling shots are not employed to tie in pile yarns.

Further objects will be apparent from the specification and drawings in which:

Figure 1 is a warpwise section of a two frame pile fabric embodying the present invention in which two filling shots per row form a lower plane and the other two shots are above the stutter to form the upper plane of the base fabric,

Figure 2 is a section as seen at 2-2 of Figure 1,

Figure 3 shows a fabric somewhat similar to Figure l but with a third frame of pile yarn introduced,

Figure 4 is a section as seen at 4-4 of Figure 3,

Figure 5 illustrates a fabric with the same weave as Figure 1 but in which one wire of each pair is a cutting wire,

Figure 6 is a weave similar to Figure 5 using pairs of undulating and cutting wires, one in each pair,

Figure 7 is a schematic weftwise view of the fabric of Figure 6 after the wires are withdrawn showing the relative pile heights in each row,

Figure 8-shows a fabric with the same ground weave as the fabric of Figures l-6 in which there are pairs of various types of wires but with each pair containing the same type,

Figure 9 is a section as seen at 99 of Figure 8,

Figure 10 shows a two shot fabric similar to Figure 8 using pairs of high and low round wires, pairs of high and low cutting wires, and with three filling wefts below the stutfer warp for each filling weft above the stuffer w p,

Figure 11 is a section as seen at 1111 of Figure 10.

Figure 12 shows a velvet fabric incorporating. the present invention with a conventional base fabric weave but in which the pile yarns weave over difierent wires in each row and through to the back, and

Figure 13 is a detail showing the fabric of Figure 8 with the first two pairs of wires withdrawn.

The invention comprises essentially the provision of pairs of pile wires over which pile yarns weave to form the same transverse row of pile projections. Each set or frame of pile yarns weaves only over one of the pairs of pile wires and under the other. It has been found that when the pile wires are withdrawn, assuming that the wires are of the same type, the pile loops or projections for some reason or other do not automatically align themselves weftwise of the fabric but still maintain their identity and appearance as different rows despite. the fact that all of the pile projections in each row are tied in under the same filling wefts. Preferably the pile wires in each pair are the same type, for example, either plain round wires which form loop pile or cutting wires to form tufts. However, the wires of each pair may be of different height or of different type in order to give a more textured appearance or to provide a combination cut and uncut pile surface. A special weave of ground fabric provides ample tuft bind and backing weight without the necessity of tying in the pile yarns on every other weft insertion.

Referring now more particularly to the drawings, Figure 1 illustrates a preferred form of the invention in which one chain warp 15 weaves alternately under and over the filling wefts 16 and 17. The other chain warp 18 weaves under two successive bottom filling wefts 19, 19 and over alternate upper filling wefts 16, 16. Wefts 19 are inserted with the stutter warps 2t raised so that these two wefts are always below the stulferwarps 20 and thus form the lower plane of the base fabric. The upper filling wefts 16 are not used to tie in either of the pile yarns which comprise the pile frames 21 and 22'. For this purpose only the upper filling wefts 17, 17 are employed. Particular attention is directed to the manner in which the pile yarns of frames 21 and 22 weave around the pile wires 23 and 24. All the yarns of frame 21, for example, weave over wire 23 and under wire 24, whereas all the yarns of frame 22 weave over wire as and under wire 23. The yarns of both frames 21 and 22, however, are tied in under upper wefts 17, 17 and when the wires 23 and 24 are withdrawn, pile loops as and 27 are formed. These loops, however, maintain their separate identity weftwise of the fabric and do not move into alignment with each other. As indicated, an important feature of the invention resides in the reversal of the pile carrying harnesses in the loom in each row without lowering the pile yarns to weave under a top filling shot or weft. This reversal is accomplished by holding the position of the pile yarn harnesses partly elevated so that the shuttle carrying the top weft shot 16 passes under all of the pile yarns instead of over them. This cycle is so arranged that the pile yarn harnesses reverse for adjacent pairs of wires but all of the pile is dropped to a bottom position in between pairs of pile wires or, in other words, after every second pile wire insertion.

In the showing of Figure 3 an additional frame of pile yarn 30 may be introduced to weave along with the upper chain warp 15 for the purpose of concealing the chain warps to best advantage and to provide more density in the base. In Figure 5 we use identical pairs of pile wires but one pile wire of each pair is not identical to the other pile wire in the same pair. In this case a cutting wire 31 is used with a high round wire 23 which when withdrawn provides the fabric shown at the right of Figure 5. There will be both out and uncut pile yarns in each row but half. of the pile projections will be cut tufts and the other half will be uncut loops. Here again it has been foundthat the pile loops 26a do not 3 align themselves weftw-ise with the pile projections 32 formed by wires 31, 31.

Figure 6 illustrates a diiferent embodiment in which a profile or undulating" wire is employed with a cutting wire in each pair. In this construction we then have high loop pile projections 33, medium size loop pile projections 34 which may be approximately of the same height as the tuft legs 35, 35, and in addition, low uncut pile areas formed by loops 36, 36 which will be lower than and therefore concealed by the pile tufts 35, 35. The relative heights of the undulating pile loops 37 in each row as compared to the height of the pile tufts 35 in each row is graphically illustrated in Figure 7 for any warpwise row.

In Figure 8 the types of pile wires vary in the same fabric but the wires of each pair are identical. For example, a pair of relatively low undulating wires 40, 40 is used in conjunction with a pair of relatively high undulating wires 41, 41. Likewise a pair of undulating wires 42, 42 provided with knives can be used with higher undulating cutting wires 43, 43. There obviously will be a wide range in the manner in which different types of wires can be planted to give the desired appearance and effect to the pile yarns.

In Figures 10 and 11 the pile yarns 45 and 46 weave over a pair of relatively low round wires 47, 47, a pair of relatively high round wires 48, 48, a pair of low cutting wires 49, 49, and a pair of high cutting wires 50, 50. In this embodiment, however, theground fabric is varied so that the intermediate or alternate filling wefts 16, 16 are lowered to the position shown at 16a in Figure 10 thus providing three lower filling wefts 19, 19 and 16a. The base fabric in the showing of Figure 10 has therefore one upper filling weft 17 for each three lower filling wefts 19 and 16a for each weaving cycle.

Figure 12 illustrates the invention embodied in a pile fabric having stuffer warps 20, a series of upper filling wefts 55, 55, and lower filling wefts 56, 56. These filling wefts are held in place by means of two chain warps 57 and 58 which interweave therewith to provide a conventional base fabric. One frame of pile warps S9 weaves over a low round wire 60 and under the subsequent low round wire 61. Likewise the other frame of pile yarn 62 weaves under pile wire 60 and over pile wire 61. These wires run in identical pairs 60, 61, 62, 63, and 64, 65. However, all of the yarns weave through to the back and are tied in under one of the bottom wefts 56 preferably alternate wefts forming each transverse I row.

To better illustrate the appearance of the fabric after the wires have been withdrawn and to show how the pile projections, particularly uncut projections, appear in the finished fabric, Figure 13 illustrates the appearance of the fabric that would be seen at the left of Figure 8 after the first two pairs of wires and 41 have been withdrawn. Despite the identical points of tie-in of the pile yarns 66 and 67, the rows of loops formed transversely of the fabric definitelytend to retain their individual position formed when woven over the wire and appear as separate and distinct transverse rows of loops. This is true regardless of whether the pile projections or loops are high or low or of other characteristics, although it becomes less noticeable in the case of the cut pile tufts.

The weaving cycle of the fabric shown in Figures 1-9 is as follows: Starting with the first bottom shot 19', as seen at the left in Figure 1, pile yarns 21 are raised by their appropriate harness to a top position, pile yarns 22 are held by their harness in a mid position along with chain warp 15 and stuffer warps 20. Chain warp 18 is in the bottom position. The first wire 23 of the pair and bottom shot 19 are inserted. Next the pile yarn harness is reversed and the chain warp harness is reversed. Top filling weft 16 is then inserted below both pile yarn frames, under chain warp 18, over chain warp 1S and stufiers 20, the latter two of which are dropped to a bottom position. Then chain warp 18 is dropped to a bottom position, stufiers 20 and chain warp 15 are raised to a middle position,-the pile yarn harnesses remain as before but reversed with respect to the insertion of the previous bottom shot, the second pile wire 24 of the pair and another bottom shot are then inserted, and

after beat up by the reed which occurs after the insertion of any filling weft, all warps except chain 15 are dropped to the bottom position for the insertion of filling wefts 17 to tie in both frames of pile yarn.

The modified cycle for Figures 10 and 11 is the same as that described in conjunction with Figures 1-9 except that the stutter warps 20 are raised instead of lowered when the filling shots 16 are inserted. This elevation of the stuffer warps 20, of course, converts the filling shots 17 from upper shots in the plane above the stuifers to lower wefts below the stutfer as seen clearly in Figure 10. The weave in Figure 12 is entirely conventional with regard to the operation of the chain warps and the stuifer warps.- However, it is to be noted that the pile yarn harnesses are reversed between insertion of the wires of each pair without lowering the pile yarns to a bottom position thus preventing them from weaving under three successive wefts.

Unexpectedly, the weave described herein provides satisfactory coverage and pile yarn density utilizing a minimum length of unexposed pile yarns since the yarns are tied in under every fourth filling weft instead of under every second filling weft. The provision of a two shot fabric in this weave serves to stiffen the backing fabric for the requisite dimensional stability of such a pile fabric. A wide variation of texture effects and color effects can be employed since the yarns in each frame may also be varied with regard to color, weight, and type, if

desired.

Having thus described our invention, we claim:

1. The method of weaving a two shot multi-frame velvet pile fabric having pile warps, filling wefts, and chain warps which comprises the steps of maintaining a chain warp in a bottom shed position, raising one frame of pile warps to a top shed position, raising another frame of pile warps to a mid shed position, maintaining another chain warp in a mid shed position, inserting a pile wire between the pile warp frames, simultaneously inserting a filling weft between the chain warps, reversing the chain warps, inserting a second filling weft between the chain warps and under both pile warp frames, reversing the chain warps, reversing the pile warp frames, inserting a second pile wire between the pile warp frames, simultaneously inserting a third filling weft between the chain warps, maintaining the chain warps in the last position, lowering both pile warp frames to a bottom shed position, and inserting a fourth filling weft over both pile warp frames and one chain warp.

2. The method of claim 1 in which the pile wires are of different characteristics.

3. The method of claim 1 including the steps of repeating the weaving cycle using pile wires of different characteristics in subsequent cycles.

4. The method of weaving a two shot multi-frame velvet pile fabric having pile warps, filling wefts, and chain warps which comprises the steps of maintaining a chain warp in a bottom shed position, raising one frame of pile warps to a top shed position, raising another frame of pile warps to a mid shed position, maintaining another chain warp in a mid shed position, raising a stuffer warp to a mid shed position, inserting a pile wire between the pile warp frames, simultaneously inserting a filling weft between the chain warps, reversing the chain warps, low ering the stulfer warp to a bottom shed position, inserting a second filling weft between the chain warps and under both pile warp frames, reversing the chain warps, reversing the pile warp frames, raising the stuffer warp to a mid shed position, inserting a second pile wire between the pile warp frames, simultaneously inserting a third filling weft between the chain warps, maintaining the chain warps in the same position, lowering the stulfer warp to a bottom shed position, lowering both pile warp frames to a bottom shed position, and inserting a fourth filling weft over both pile warp frames, one chain warp, and the stuifer warp.

5. The method of weaving a two shot multi-frame velvet pile fabric having pile warps, filling wefts, and chain warps which comprises the steps of maintaining one chain warp in a mid shed position, maintaining another chain warp in a bottom shed position, maintaining the stuffer warp in a mid shed position, maintaining one frame of pile warps in a top shed position, maintaining another frame of pile warps in a mid shed position, inserting a pile wire between the pile warp frames, simultaneously inserting a filling weft between the chain warps, reversing the chain warps, inserting a second filling weft between the chain warps below the pile warp frames and the stutfer warp, reversing the pile warp frames, reversing the chain warp frames, maintaining the stutfer warp in a mid shed position, inserting a pile wire between the pile warp frames, simultaneously inserting a third filling weft between the chain warps and under the stuffer warp, maintaining the chain warps in the same shed positions, lowering all other warps to a bottom-shed position, and inserting a fourth filling weft above the pile warp frames and the stuffer warp.

6. The method of weaving a two shot multi-frame velvet pile fabric having pile warps, filling wefts, and chain warps which comprises the steps of maintaining one pile warp frame in top shed position, maintaining another pile warp frame in a mid shed position, maintaining one chain warp in a mid shed position, maintaining another chain warp in a bottom shed position, inserting a pile wire between the pile warp frames, simultaneously inserting a filling weft between the chain warps, reversing the chain warp frames, reversing the pile warp frames, inserting a second filling weft between the chain warps and under the pile warp frames, maintaining the chain warps in the same positions, inserting a pile wire between the pile Warp frames, simultaneously inserting a third filling weft between the chain warps, reversing the chain warps, lowering all other warps to a bottom shed position, and inserting a fourth filling weft between the chain warps and over all other warps.

7. The method of weaving a two shot multi-frame velvet pile fabric having pile warps, filling wefts, and chain warps which comprises the steps of maintaining one pile warp frame in a top shed position, maintaining another pile warp frame in a mid shed position, maintaining one chain warp in a mid shed position, maintaining another chain warp in a bottom shed position, maintaining a stutfer warp in a bottom shed position, inserting a pile wire between the pile warp frames, simultaneously inserting a filling weft between the chain warps, reversing the chain warps, reversing the pile warp frames, raising the stuffer warp to a mid shed position, inserting a second filling weft between the chain warps and under the pile warp frames, maintaining the chain warps and the pile warps in the same positions, lowering the stutfer Warp to a bottom shed position, inserting a pile wire between the pile warp frames, inserting simultaneously a third filling weft between the chain warps, reversing the chain warps, raising the stufier warp to a mid shed position, lowering all pile warps to a bottom shed position, and inserting a fourth filling weft between the chain warps and over the pile and stulfer warps.

No references cited. 

